U.S. patent number 4,963,045 [Application Number 07/413,236] was granted by the patent office on 1990-10-16 for dispenser-applicator for spreading substances.
This patent grant is currently assigned to The Willcox Family Trust. Invention is credited to Nancy A. Willcox.
United States Patent |
4,963,045 |
Willcox |
October 16, 1990 |
**Please see images for:
( Certificate of Correction ) ** |
Dispenser-applicator for spreading substances
Abstract
An applicator adapted for storing and spreading pre-measured
portions of liquid, gel, creamy, low-melting semi-solid or solid
substances on surfaces is disclosed. The applicator has a rigid
base and a thin flexible cover attached to one side of the base to
form, together with the base, a collapsible pocket for storing the
substance. A handle is attached to the other side of the base. The
thin, flexible cover includes one or more apertures wherethrough
the substance contained in the pocket may flow out of the pocket. A
protective sealing member, such as a thin film, is removably
attached to the exterior of the flexible cover to seal or protect
the apertures until the sealing member is removed from the cover.
The flexible cover collapses as the substance is squeezed out of
the pocket while it is being applied to a desired surface. When the
substance contained in the applicator is a low-melting solid or
semi-solid, the substance melts or becomes flowable as it comes
into contact with a warm surface on which the substance is to be
spread.
Inventors: |
Willcox; Nancy A. (Costa Mesa,
CA) |
Assignee: |
The Willcox Family Trust (Costa
Mesa, CA)
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Family
ID: |
26728839 |
Appl.
No.: |
07/413,236 |
Filed: |
September 27, 1989 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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50910 |
May 15, 1987 |
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Current U.S.
Class: |
401/132; 206/440;
222/107; 401/12; 401/184 |
Current CPC
Class: |
A45D
34/04 (20130101); B05C 17/00 (20130101); A45D
2200/1018 (20130101) |
Current International
Class: |
A45D
34/04 (20060101); B05C 17/00 (20060101); B65D
085/74 () |
Field of
Search: |
;401/6,12,132,176,184,185,261,265,196,263,262 ;15/29R ;222/95,107
;206/277,440 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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945918 |
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Apr 1974 |
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CA |
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0078596 |
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Nov 1983 |
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EP |
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1628564 |
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Feb 1971 |
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DE |
|
Primary Examiner: Johnson; Richard J.
Attorney, Agent or Firm: Burns, Doane, Swecker &
Mathis
Parent Case Text
This application is a continuation, of application Ser. No.
07/050,910, filed May 15, 1987.
Claims
What is claimed is:
1. A dispenser-applicator for dispensing a substance contained
therein to a receiving surface and for spreading the substance on
the receiving surface, the dispenser-applicator comprising:
a substantially rigid base having a generally continuous smooth
surface grippable handle means; and
a thin flexible substantially impervious plastic film sealed to the
base so as to form a sealed collapsible pocket between the film and
the surface of the base for containing the substance;
wherein the thin flexible plastic film is adapted to contact the
receiving surface and has at least one aperture for dispensing the
substance therethrough and onto the receiving surface by
application of pressure on the base to collapse the pocket between
the surface of the base and the receiving surface; wherein the film
is positioned on the base such that as the pocket collapses the
film moves toward the surface of the base and wherein the film is
sufficiently thin and flexible such that (a) the film itself
provides no significant resistance to the pressure applied to the
base and essentially all pressure applied to the base transfers to
the substance in the pocket, (b) the film conforms to the shape of
the substance in the pocket when pressure is applied and remains in
the shape of the substance in the pocket when the pressure is
released and (c) the film distributes the applied pressure over the
receiving surface and spreads the substances on the receiving
surface of the dispenser-applicator is moved across the receiving
surface.
2. A dispenser-applicator according to claim 1 comprising a sealing
member removably attached to the exterior of the thin flexible film
to seal at least one aperture.
3. A dispenser-applicator according to claim 1 comprising a
protective cover removably attached to the exterior of the
dispenser-applicator to protect the thin flexible film.
4. A dispenser-applicator according to claim 2 comprising a
protective cover removably attached to the exterior of the
dispenser-applicator to protect the thin flexible film and sealing
member.
5. A dispenser-applicator according to claim 3 wherein the
protective cover comprises an enclosure means for containing the
dispenser-applicator.
6. A dispenser-applicator according to claim 2 wherein the sealing
member is adhered to the thin flexible film by inherent chemical or
physical attractive forces between the sealing member and the thin
flexible film.
7. A dispenser-applicator according to claim 3 wherein the
protective cover is removably sealed to the dispenser-applicator in
a substantially leak-proof manner.
8. A dispenser-applicator according to claim 1 wherein the side of
the base facing the pocket is substantially flat.
9. A dispenser-applicator according to claim 1 wherein the thin
flexible film is sealed to the base so as to form a plurality of
pockets, wherein there is at least one aperture in each portion of
the film forming each pocket.
10. A dispenser-applicator according to claim 1 wherein a portion
of one edge of the base contains notches.
11. A dispenser-applicator according to claim 1 wherein a portion
of one edge of the base is a curved surface.
12. A dispenser-applicator according to claim 1 wherein a substance
is present in the pocket.
13. A dispenser-applicator according to claim 12 wherein the
substance comprises a liquid or a viscous liquid.
14. A dispenser-applicator according to claim 12 wherein the
substance comprises a gel, a cream or a thixotropic material.
15. A dispenser-applicator according to claim 12 wherein the
substance comprises a medical ointment.
16. A dispenser-applicator according to claim 13 wherein the
substance comprises a medicinal ointment.
17. A dispenser-applicator according to claim 14 wherein the
substance comprises a medicinal ointment.
18. A dispenser-applicator according to claim 12 wherein the
substance comprises a food, an adhesive, a lubricant or a cleaning
agent.
19. A dispenser-applicator according to claim 13 wherein the
substance comprises a food, an adhesive, a lubricant or a cleaning
agent.
20. A dispenser-applicator according to claim 14 wherein the
substance comprises a food, an adhesive, a lubricant or a cleaning
agent.
21. A dispenser-applicator according to claim 12 wherein the
substance comprises a solid which becomes capable of flowing under
pressure upon contact of the thin flexible film with the receiving
surface.
22. A dispenser-applicator according to claim 21 wherein the
substance is a solid which melts when the flexible film contacts a
receiving surface which is warmer than the substance.
23. A dispenser-applicator according to claim 22 wherein the
substance comprises a medicinal ointment.
24. A dispenser-applicator according to claim 22 wherein the
substance comprises a food, an adhesive, a lubricant or a cleaning
agent.
25. A dispenser-applicator according to claim 24 wherein the food
comprises butter or margarine.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a dispenser-applicator adapted
for applying spreadable substances to solid surfaces. More
particularly, the present invention is directed to a
dispenser-applicator for applying pre-measured convenient amounts
of spreadable substances, such as liquids, gels, lotions, and
readily melting solids, to surfaces.
2. Brief Description of the Prior Art
Spreading various substances, such as lotions, ointments, gels,
lubricants, skin medications, as well as liquidy or pasty
foodstuffs, on solid surfaces, and frequently on irregular
surfaces, is very old in the art. Spreading of lotions or
semi-solid creamy or pasty external medications on various parts of
the human body, and the application of butter to corn-on-the-cob
may be mentioned in this connection as specific examples where a
convenient, preferably pre-measured relatively small portion of a
spreadable substance is to be applied preferably evenly to an
irregular surface.
In view of the nature and ubiquitousness of the problem in human
experience, it is perhaps not surprising that a very large number
of dispenser devices adapted for various types of specific
applications have been described in the prior art.
U.S. Pat. No. 3,334,374, for example, discloses an applicator pad
having a liquid impermeable back wall, and a liquid permeable front
wall with a pocket or storage space being formed between the two.
The front wall may be a perforated sheet or an absorbent material.
A liquid agent to be applied with the applicator pad is kept in
rupturable capsules within the pocket When the applicator pad is
pressed sufficiently firmly against a surface, the capsules are
ruptured, and the liquid is applied to the surface through the
front wall.
U.S. Pat. No. 2,961,677 discloses an applicator for a single dose
of shoe polish or the like, having a porous pad. A pocket for
liquid or liquidy paste is formed from a pierceable plastic
material on one side of the porous pad in such a manner that during
normal storage the liquid is isolated from the pad. A gripping
member or handle is mounted to the plastic material leaving the
front surface of the pad available for contact with a surface upon
which the liquid is to be spread. When it is desired to use liquid
or liquidy paste, the plastic wall separating the porous pad from
the liquid is pierced with a needle and the liquid is slowly
squeezed out to the surface through the pores of the pad.
U.S. Pat. No. 4,291,697 discloses a cleaning or applicator device
which has a frangible capsule of liquid embedded in a relatively
flat sponge member. The sponge embedding the capsule is mounted to
an elongated handle. When it is desired to apply the liquid
contents of the capsule with the sponge, pressure is exerted on the
sponge to break the embedded capsule, and the liquid is allowed to
soak into the sponge.
U.S. Pat. No. 4,430,013 describes an applicator for a liquid
substance having a foam pad, and a liquid reservoir attached to one
side of the pad. The liquid reservoir, although made of relatively
rigid plastic, has a weakened portion, caused, for example, by a
slit or scoring, so that pressure exerted in a given direction, or
bending of the rigid plastic, breaks the weakened portion. When the
weakened portion breaks, the liquid spills into the foam pad and is
applied therefrom to a desired surface.
An applicator device somewhat similar in construction and operation
to the just-described patented device is disclosed in U.S. Pat. No.
4,493,574. The "dispenser package" of the U.S. Pat. No. 4,493,574
has a flexible pouch adhered to a relatively stiff material. The
package may be opened along a fault line or cut pattern in the
stiff material by bending or flexing the stiff material in a
V-shaped pattern. The dispenser package of this patent serves
reasonably well for storing and dispensing single doses of liquid
substances or liquidy pastes especially in situations where even
spreading on a surface is not important. For example, the dispenser
package of U.S. Pat. No. 4,493,574 serves reasonably well for
dispensing certain liquidy or liquidy-pasty food condiments, such
as mustard, ketchup, or honey.
U.S Pat. No. 4,493,574 also describes an embodiment of a dispenser
package which contains a sponge to catch the liquidy substance when
the overlying stiff material is broken along a fault line. This
embodiment is said to be suitable for applying the liquidy
substance to a surface in a "swab" type application. In reality,
however, this device, due to its particular configuration and due
to the presence of the relatively sharp edges of the broken stiff
material, is not well suited for evenly spreading a liquid on any
surface. This device is particularly ill suited for an application
where the surface (such as a wounded skin) is sensitive to touch,
pressure, or damage by the broken stiff material. The device of
U.S. Pat. No. 4,493,574 is also not well suited for dispensing
solid or semi-solid substances, and particularly not suited for
relatively evenly dispensing and spreading solid or semi-solid
substances on a solid surface, and even less so on an irregular
surface.
Generally speaking, those dispensers and applicators of the prior
art which aim to dispense a convenient single portion or dose of a
spreadable material (for example, the applicator packages of U.S.
Pat. Nos. 4,430,013 and 4,493,574) tend either to be unable to
dispense all of their contents, or to dispense the contents in a
poorly controlled manner and therefore waste the spreadable
material. This is clearly undesirable.
For more background and detailed information on the prior art to
the present invention, further reference is made to the following
U.S. Pat. Nos. 2,829,393; 3,014,579, 3,214,781; 3,768,916;
3,818,911; 3,826,259; 3,896,808; 4,148,318; 4,173,978; 4,183,684;
4,240,760; 4,515,703, and to Canadian Patent No. 945918.
In light of the foregoing, it is apparent that the relatively large
number of patent disclosures and devices developed in the prior art
for dispensing liquid and pasty materials as well as for applying
them on various surfaces, have not solved all problems related to
this art. There is still further serious need in the art for
dispensers and applicators well adapted for dispensing and applying
convenient amounts, preferably single doses, in a well-controlled
manner, not of just liquids but also of gels, semi-solids, and
certain solids (such as butter), on solid surfaces. The present
invention provides such applicator and dispenser devices.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a
dispenser-applicator adapted for dispensing a pre-measured dose or
portion of a liquid substance, and for applying the same to smooth
or rough, regular or irregular solid surfaces.
It is another object of the present invention to provide a
dispenser-applicator adapted for dispensing a pre-measured dose or
portion of a solid or semi-solid substance which flows out from the
applicator to be applied to any solid smooth or rough, regular or
irregular surface, when the surface contacts the applicator and is
sufficiently warm to melt the substance inside, or lower its
viscosity sufficiently to make the substance flow under application
of pressure.
It is still another object of the invention to provide a
dispenser-applicator for pre-measured or convenient doses of
medicinal ointments, solutions, and the like, which is particularly
non-traumatic when used on broken, sensitive or injured skin,
superficial wounds, or the like.
Generally speaking, it is an object of the present invention to
provide a dispenser-applicator for pre-measured portions (or less)
of liquid, gel, creamy, semi-solid or solid substances which can be
relatively slowly released in a controlled manner from the
applicator onto a surface as a result of applying motion and
pressure, or in the case of solids and semi-solids as a result of
applying sufficient heat to the applicator to cause a phase
transition or marked drop in the viscosity of the contents of the
applicator.
The foregoing objects and advantages are attained by an applicator
having a substantially rigid base, and a thin flexible cover formed
so as to create a dimensional cavity, which is bonded to the base
to create a sealed collapsible pocket together with the base. A
handle is attached to, or forms an integral part of, the side of
the base opposite to where the cover forms the pocket with the
base. The thin flexible cover includes at least one aperture
wherethrough the substance contained in the pocket may flow out of
the pocket. A protective sealing member, such as a flexible film or
thin rigid material, is removably attached to the exterior of the
flexible cover to seal the apertures until the protective sealing
member is removed from the cover. The substance contained in the
pocket may be a liquid, gel, cream, semi-solid or solid. When the
substance is a liquid, the pocket may also contain a foam or like
absorbent material to contain the liquid in its pores and allow it
to be dispensed in a more controlled manner than in the absence of
such absorbent material When the substance is a gel, cream,
semi-solid or solid, it is of such a nature that either application
of pressure or heat, or both, causes the substance to melt or
substantially decrease its viscosity, or otherwise flow whereby the
substance may be dispensed to a surface through the apertures of
the flexible cover.
The substance, liquid, gel, cream, lotion, semi-solid, or low
melting solid of the above-described nature, is applied to a
surface after the protective sealing member is removed from its
position on the cover sealing the apertures. The flexible cover is
then pressed against the surface while the user holds the
applicator by the handle. The flexible cover substantially conforms
to the surface. If the contents are a liquid, gel, cream, lotion,
or other "thixotropic" substance, gentle pressure on the applicator
is sufficient to cause the substance to flow out to the surface
while the substance is spread on the surface by lateral motion of
the applicator. When the contents are a low melting solid or
semi-solid, then melting or softening of the solid or semi-solid on
contact with a "warm" surface combined with gentle pressure and
lateral motion by the user, applies the substance to the desired
area of the surface. "Warm" surface in this respect means a surface
which has a temperature near to, or preferably above, the melting
or softening temperature of the solid or semi-solid contents of the
applicator. For example, a pre-measured portion of solid butter can
be readily and conveniently spread on a warm or hot corn-on-the-cob
with the applicator of the present invention.
The features of the present invention can be best together with
further objects and advantages, by reference to the following
description, taken in connection with the accompanying drawings,
wherein like numerals indicate like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the first preferred embodiment of
the applicator-dispenser device of the present invention with a
protective sealing member omitted from the view;
FIG. 2 is a bottom view of the first preferred with a protective
sealing member being omitted from the view;
FIG. 3 is a cross-sectional view, the cross-section being taken on
lines 3,3 of FIG. 2;
FIG. 4 is an enlarged view of the area indicated at 4 on FIG.
3;
FIG. 5 is a cross-sectional view of the second embodiment of the
applicator-dispenser device of the present invention, with a
protective sealing member being omitted from the view;
FIG. 6 is a bottom view of the first or second preferred
embodiment, the view showing a first size of protective sealing
member being lightly adhered or peelably sealed in place in the
device;
FIG. 7 is a cross-sectional view of the first preferred embodiment
with the protective sealing member being in place in the device,
the cross-section being taken on line 7,7 of FIG. 6;
FIG. 8 is a bottom view of a third preferred embodiment of the
applicator-dispenser device of the present invention, the view
showing a second size of protective sealing member peelably sealed
in place on the device;
FIG. 9 is a cross-sectional view, the cross-section being taken on
lines 9,9 of FIG. 8;
FIG. 10 is a bottom view of a fourth preferred embodiment;
FIG. 11 is a cross-sectional view of the fourth preferred
embodiment the cross-section being taken on lines 11,11 of FIG.
10;
FIG. 12 is a bottom view of a fifth preferred embodiment;
FIG. 13 is a cross-sectional view of the fifth preferred
embodiment, the cross-section being taken on lines 3,13 of FIG.
12;
FIG. 14 is a bottom view of the fifth preferred embodiment with the
protective sealing member removed;
FIG. 15 is a bottom view of a sixth preferred embodiment;
FIG. 16 is a cross-sectional view of the sixth preferred
embodiment, the cross-section being taken on lines 16,16 of FIG.
15;
FIG. 17 is a perspective view of a seventh preferred embodiment
with a protective sealing member omitted from the view, and
FIG. 18 is a cross-sectional view of the seventh preferred
embodiment, the cross-section being taken on lines 18,18 of FIG.
17.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following specification, taken in conjunction with the
drawings, sets forth the preferred embodiments of the present
invention. The embodiments of the invention disclosed herein are
the best modes contemplated by the inventors for carrying out their
invention in a commercial environment, although it should be
understood that several modifications can be accomplished within
the parameters of the present invention.
Referring now to FIGS. 1-4 and 6-7 of the appended drawings, a
first preferred embodiment 20 of the applicator-dispenser device of
the present invention is disclosed. It should be noted at the
outset that the applicator-dispenser device of the present
invention is best adapted for storing and dispensing a relatively
small amount of a substance which is thereafter desired to be
spread, preferably relatively evenly, on a surface (not shown).
Preferably, and in most applications of the invention, the
dispenser-applicator holds a single convenient portion of the
substance, although it should be understood that the user controls
dispensing such that only the desired amount need be dispensed.
The substance itself can be a liquid, cream, gel, or semi-solid
material, the physical properties of which are such that the
material flows readily upon application of pressure. Liquid
materials naturally flow readily even without pressure. Creams,
gels, and like materials, generally speaking, flow readily only
under pressure; sometimes such materials are "thixotropic" in the
sense that their viscosity actually decreases once motion is
attained under pressure.
Alternatively, and particularly when the substance is solid, it
must be of such a nature that it melts readily or becomes capable
of flowing under pressure when the dispenser-applicator comes into
contact with the warm surface to which the substance is to be
applied. Warm surface in this respect means a surface which is of
sufficiently high temperature to cause melting, or the
above-described viscosity change of the solid substance.
Generally speaking, the dispenser-applicator of the invention can
be used for storing and dispensing liquid, creamy or cream-like,
gelatinous, semi-solid or solid substances in a wide variety of
fields of application. More specifically, the substance stored and
dispensed by the dispenser-applicator of the invention may be a
food item, such as butter, margarine, mustard, ketchup, honey, or
liquidy or creamy condiment. The substance may be in the cosmetic
or health-care field, for example, a shampoo, body-lotion, or
medicinal lotion or ointment. Alternatively, the
dispenser-applicator may contain a convenient amount for a one-time
application of a household or industrial cleaning agent, or a
material which has industrial or like application. For example, the
substance may be a small portion (single portion) of adhesive or
lubricating oil. It should be specifically understood in this
regard that the present invention is not limited by the field of
application of the substance which is dispensed from the novel
dispenser-applicator.
Referring now again back to FIGS. 1-4 and 6-7, the first preferred
embodiment 20 of the dispenser-applicator of the invention includes
a substantially rigid base 22. The base 22, however, does not have
to be absolutely rigid. If the dispenser-applicator is to be
applied to a curved surface, the base 22 may be semi-rigid so as to
allow the user to contour the base by applying finger pressure thus
causing the dispenser-applicator to conform somewhat to the
underlying curved surface. It should be understood that in this
document, the term "substantially rigid" is meant to include
semi-rigid and rigid. The base 22, as shown, is rectangular in the
horizontal plane, although this shape is not critical and any other
shape may be used. The base 22 is preferably made of plastic and
can be made by such conventional technology as thermoforming or
injection molding. However, metal, such as a thin aluminum
stamping, may be suitable for some applications. In this regard it
is noted that selection of material for the base 22 depends on the
type of application, that is, the type of substance to be stored in
the dispenser-applicator. For certain applications rigid polyvinyl
chloride (pvc) may be suitable for the base 22; for certain
medicinal and food distributing applications other plastics, such
as a rigid polyester or high impact polystyrene, may be used.
What is important about the base, in light of the foregoing, is
that the material and thickness be chosen to provide the desired
rigidity or semi-rigidity, that the material may be compatible with
the contents and provide adequate chemical and physical barrier
properties, that the material be compatible with the cover material
in terms of chemical stability, and that the cover and base be
bondable to each other in surface-to-surface contact or by means of
an intermediate material. What is also important about the base is,
where it is desired to leave minimal residual contents in the
dispenser-applicator, and where the surface of application is
relatively flat along the area of contact between the
dispenser-applicator and said surface, that the inner surface of
the base should be substantially flat. If, however, a
dispenser-applicator is to be made specifically for use on a
particular convex curved surface, for example, a cylindrical
surface such as a pipe, or a spherical surface such as a ball, then
the base can be formed with an inherent curvature so as to
substantially conform to the surface of application as the cover
collapses. Inverse curvature of the base to fit concave surfaces is
also possible.
In all applications, the surface of the base is generally
continuous, to provide the desired chemical and physical barrier
properties mentioned above, and generally smooth, to provide the
desired dispensing and application action as discussed herein.
A handle 24 is affixed to one side of the relatively flat base 22.
In the herein-described first preferred embodiment 20 the handle 24
is bar shaped, and is integrally constructed, for example, molded,
with the base 22. The purpose of the handle 24 is to enable the
user (not shown) to conveniently hold and gently press the
dispenser-applicator 20 against a surface (not shown) to which the
contents are to be applied. For automated applications, the handle
24 may be configured for optimum gripping by, or attachment to, a
machine rather than by human hands.
In alternative embodiments the base may be bonded to the handle so
as to make the base substantially rigid by virtue of being affixed
to the handle, even though the material of the base may be flexible
or resilient. For example the handle may be hollow and the base may
be a member stretched between two opposite ends of the handle.
A flexible cover 26 is affixed to the base 22 on the side which is
opposite to the location of the handle 24. The flexible cover 26
preferably comprises a relatively thin sheet of plastic material,
for example, 2.00 mil thick film of polyester. The cover 26 may
also be a multi-layered film rather than a single layer. For
example, the cover 26 may be a metallized plastic film, or a
laminate of foil and film, or a film possessing multiple layers of
different types of plastic with or without metal.
Selection of material for the flexible cover 26 also depends on the
particular field of application, or stated differently, on the type
of substance dispensed by the applicator-dispenser device of the
invention. For example, where it is required to have a cover 26
possessing relatively low water vapor transmission and low oxygen
transmission, a dual-layer film such as
polypropylene/polyvinylidene chloride is one choice, or another
choice is metallized polyester. There are still additional choices
with substantially equivalent properties. A certain degree of
flexibility, sufficient to collapse under gentle pressure while the
contents are dispensed, compatibility with the stored substance,
and adequate tear strength and abrasion resistance for the intended
application are important requirements for the flexible cover 26
The stored substance bears the reference numeral 28 on the drawing
Figures.
Generally speaking, specific plastic or metallized plastic
materials are chosen in accordance with the state of packaging
arts, for the base 22 and cover 26, such that they possess the
physical/chemical barrier properties required to store the specific
desired contents, and such that they possess the respective
mechanical requirements described above for rigidity or
flexibility. The materials are also selected on the basis of
characteristics required to accomplish the bond or seal between
cover and base, and to tolerate any processing regimen required,
such as heating or various methods of sterilization. Many choices
of materials exist for each application of the
dispenser-applicator. For one embodiment of the present invention
which dispenses butter, the base 22 comprises 10 to 15 mil thick
(near the periphery) semi-rigid polyester, and the cover 26 is a
flexible 2 mil thick composite film of polyester/polyvinylidene
chloride, the latter surface of which is coated with a heat sealant
layer of low density polyethylene. The cover and base are affixed
together by sealing the periphery with heat and pressure
(heat-sealing).
For the purposes of this description, the term "heat sealing"
includes all techniques where heat is directly applied or induced
in opposed surfaces such that at least part of the underlying
material is melted so as to bond the opposed surfaces together.
Thus, heat sealing in the present description includes the
techniques of ultrasonic welding, dielectric heating, and
radio-frequency welding.
In the herein-described first preferred embodiment 20 the flexible
cover 26 is bonded to the periphery of one side of the base 22 by a
suitable adhesive. On FIG. 4, an adhesive 30 is shown between the
cover and the base. However, this illustration is also meant to
convey bonding in a broader sense, so that item 30 on the drawing
may also represent a layer of heat-sealant material which has been
melted and thereby bonded to the cover and the base; or
alternately, the cover and the base materials have been fused
together directly by heat and pressure and item 30 is indicative of
the zone of fusion.
In alternative embodiments the flexible cover 26 may itself
comprise a film including a heat sealable layer, and may be
attached to the base 22 by heat sealing. In another alternative
embodiment, the base rather than the cover may have an integral
layer of material which provides the capability for heat-sealing.
Also, another embodiment is where neither the cover nor base
inherently possess a heat-sealant layer, but rather a thin film
heat-sealant layer, capable of being sealed both to the cover and
the base, is independently introduced between cover and base as
part of the assembly process to manufacture the invention.
Generally speaking, state-of-the-art plastic article manufacturing
and packaging techniques, machinery, and materials may be employed
for manufacturing the dispenser-applicator devices of the present
invention. Where it is desirable to have a metallic base,
state-of-the-art metal-forming methods may be employed.
The flexible cover 26 forms, together with the base 22 a pocket or
storage space wherein the substance 28 is contained. Referring now
primarily to the bottom view of FIG. 2, a plurality of holes or
apertures 32 are shown in the flexible cover 26 The purpose of the
holes or apertures 32 is to permit the substance 28 to flow out of
the applicator 20 when it is desired to spread the substance 28 on
a receiving surface (not shown).
As illustrated in FIG. 2 the first preferred embodiment 20 has only
three holes 32. It should be expressly understood however in this
connection that the number of holes or apertures 32 in the flexible
cover 26, and their size and spacing depend on the nature of the
substance 28, the characteristics of the surface to which the
substance is to be applied, the typical pressure used during
application and on the desired rate and pattern of flow of the
substance 28 from the dispenser-applicator 20.
Referring now further to FIGS. 6 and 7, a protective sealing member
34 is shown in contact with the bottom of the flexible cover 26 of
the first preferred embodiment 20. The protective sealing member
may be only lightly adhered or, alternately, bonded in place, to
provide a leak-proof seal, as described in detail below. In some
applications, for example when the substance 28 is a solid the
sealing member 34 may be necessary only for sanitary reasons, that
is, to the surface of the cover 26 clean. Further, where the
substance is solid and where it is desired to keep the
dispenser-applicator clean, the protective sealing member 34 may be
omitted altogether provided the dispenser-applicator (singularly or
multiply) is contained within a clean container such as a pouch or
bag which itself protects against contamination.
For certain applications, in the first preferred embodiment the
sealing member 34 is only lightly adhered to the cover 26 by weak
interactive forces which occur between the respective materials of
the sealing member 34 and the cover 26. These weak interactive
forces, primarily electrostatic or hydrophobic in nature, are
commonly termed "cling". The "cling" may also be caused (in full or
in part) by the presence of a small amount of the contents between
the cover 20 and the sealing member 34. In many applications, when
the substance is a liquid or a low viscosity gel or the like, the
protective sealing member 34 is needed not only to keep the cover
26 clean but also to seal the apertures 32 in a leak-proof manner
and thereby to retain the substance 28 in the dispenser-applicator
20.
Depending on the nature of the application, the protective sealing
member 34 may be made from several types of materials, but is
generally a thin plastic film, for example, 0.6 mil thick
polyvinylidene chloride. Because, generally speaking, the sealing
member 34 must have the same chemical barrier properties as the
cover 26, it is, generally speaking, selected from the same
materials.
The protective sealing member 34 is, of course, removably, or
peelably, attached to the flexible cover 26, so that it can be
removed before the substance 28 is to be dispensed from the
applicator 20 of the invention.
In addition to "cling", several methods known in the art, for
example weak adhesive bonding or peelable heat-sealing in a
frangible strip or the like, may be used for removably attaching
the protective sealing member 34 to the cover 26. In certain
embodiments the protective sealing member 34 is a plastic film
coated either with a heat-sealant layer (such as polyethylene) or
with a pressure sensitive adhesive.
When the protective sealing member 34 is bonded to the cover 26 in
a leak-proof manner, the area, geometry, and exact location of the
seal about the periphery of the perforations is variable. What is
important is that the seal be sufficient to prevent the contents
from escaping through the seal to the exterior. The thickness and
type of film chosen for the protective sealing member 34 depends,
in part, on the required barrier properties and method of bonding
the protective member 34 to the cover 26. The material chosen must
possess sufficient tensile strength such that it does not tear when
being peeled away from the cover. The material must also possess
sufficient cohesive strength that it does not suffer a cohesive
failure and separate internally when peeled away from the cover.
Such materials and characteristics are well known in the art of
plastic film packaging, both for heat-sealed films and adhesively
sealed films.
In one particularly important application of the present invention,
the substance 28 is solid butter which flows out of the applicator
20 only when the applicator touches a surface (not shown)
sufficiently hot to melt or soften the butter. In this application,
one embodiment of the protective sealing member 34 is conveniently
a piece of waxed paper which is "bonded" to the substantially flat
bottom of the flexible cover by "cling" caused, at least in part,
by the presence of a thin film of butter.
As a second example where butter is the contents, a cover 26 is
comprised primarily (and on the external surface) of polyvinylidene
chloride. Used in conjunction, a suitable protective member 34 is a
piece of SARAN WRAP.RTM. (Dow Chemical), which is an approximately
0.6 mil thick film of polyvinylidene chloride. This material has
the property of clinging to itself. Any residual butter on the
surface of the cover does not interfere with the clinging together
of this specified cover and this specified protective member.
As a third example where butter or ointment is the contents, the
cover is made of a 2 mil thick dual-layer film of polyester and
polyvinylidene chloride. The protective sealing member is of the
same basic composition as the cover, but also possesses a thin
layer of polyethylene, wherein the polyethylene surface provides
the heat-sealant layer and allows the protective member to be
heat-sealed to the cover in a peelable seal.
Thus, when it is desired to apply the substance 28 from the
dispenser-applicator 20, a user (not shown) grips the handle 24
with thumb and forefinger, and with the other hand removes the
protective sealing member 34 from the flexible cover 26, thereby
exposing the holes or apertures 32. The contents of the
dispenser-applicator 20 are then forced to slowly flow out to a
desired surface (not shown) by gently pressing the flexible cover
against the surface (not shown) and moving laterally about the
desired surface so as to distribute the content over the desired
area. More particularly, when the substance is a cream, gel,
lotion, or the like, then the pressure exerted by the user (not
shown) in conjunction with motion about the surface is sufficient
to slowly and gradually squeeze the contents out of the applicator
20 and substantially control the distribution of the contents about
the surface. When the substance 28 in the dispenser-applicator is a
low melting solid, such as butter, then the solid (butter) first
melts because of its contact with a warm or hot surface (not shown)
and the resulting melted butter floWs out of the applicator through
the holes 32. The flexible cover 26 gradually collapses as the
substance is released from the dispenser-applicator, so that
virtually all of the substance can be squeezed out of the
applicator 20.
Generally speaking, gentle pressure and some lateral motion is
required to dispense the contents of the applicator in a relatively
even and controlled manner, although in some cases gentle pressure
may be sufficient. The following explanation explains this issue in
detail. If the perforations 32 of the cover 26 are located
approximately centrally, then in the unusual situation when the
dispenser-applicator is applied to a very smooth flat surface and
pressed upon that surface, the contents 28 will not be dispensed
because the surface in effect presses back against the cover
sealing the periphery of each perforation. Then in order to
dispense the contents, relative motion of the dispenser-applicator
is used along the surface. Such motion combined with inherent
surface friction creates shearing forces along the plane of the
perforations, literally shearing the contents away and causing them
to be deposited in a thin layer on the surface of application.
Alternatively, using the same dispenser-applicator on a rough
surface, that is, a surface where there are surface features such
as crevices or bumps to which the area of the cover around the
perforations cannot totally conform when the dispenser-applicator
is pressed against said surface, then flow of contents can occur
without lateral motion, tending to fill those non-conformal areas
and possibly escaping out from under the dispenser-applicator away
from the periphery, depending on the degree of surface roughness.
In contrast, however, if the perforations of the cover are located
at or near the extreme periphery of the cover rather than
centrally, then when the full dispenser-applicator is applied to
either a smooth surface or a rough surface, the perforations will
be generally above the level of the surface. Then as pressure is
applied, the contents will be squeezed out of the
dispenser-applicator in directions away from its periphery at some
elevation above the surface. In view of the preceding discussion it
can be generalized that the dispenser-applicator can be configured
so as to substantially dispense its contents without lateral
motion. However, subsequent lateral motion would be required if it
is desired to redistribute the contents about the surface.
Therefore, the preferred way to use the dispenser-applicator to
accomplish relatively uniform surface distribution of contents is
typically to apply pressure and lateral motion simultaneously.
As the contents of the device are expressed from it, the cover 26
collapses and moves toward the inner surface of the base 22, so as
to approximate this surface; thus, in the preferred embodiments,
this inner surface of the base 22 is flat, or nearly flat, such
that as the cover 26 approximates this surface, there is little or
no "dead volume" in which the contained substance might be trapped
and therefore inaccessible. This characteristic of minimal dead
volume gains in importance as the contents gain in cost
In the illustrated preferred embodiment of FIG. 1, the cover is
shown as a formed film, and is produced by conventional means such
as thermoforming. For most applications of the invention, the film
comprising the cover can be formed into its final shape prior to
insertion of the contents, for example, by thermoforming. However,
in alternative embodiments the cover is initially a stretchable
flat film, and concomitant with the filling operation becomes
stretched into its final configuration. Alternatively, the cover
can be an initially shrinkable film larger than needed in final
form, is partially or completely bonded to the periphery of the
base, and at some step subsequent or concomitant to the filling
operation, is shrunk into its final smaller configuration.
FIG. 5 shows a second preferred embodiment 36 of the
dispenser-applicator of the present invention. The second preferred
embodiment 36 differs from the first preferred embodiment 20 only
in the construction of the handle 24. In the second preferred
embodiment 36, the handle 24 is a separate piece of substantially
rigid plastic and is not integrally constructed with the base 22.
Rather, it is attached to the base 22, for example, by use of a
suitable adhesive (not shown).
The handle may be configured in a variety of shapes and attached or
bonded to the base in a variety of ways known to those skilled in
the art of plastic article manufacturing. What is important about
the handle is that it be configured and sized adequately for
gripping with fingers (or for attachment to a machine) and that it
be rigid enough to allow the user to control the motion of the
dispenser-applicator.
FIGS. 8 and 9 show a third preferred embodiment 38 of the
dispenser-applicator of the present invention for use with liquid
contents. In this embodiment 38, the protective sealing member 34
is an elongated strip of material which covers and peelably seals
the apertures 32 in a leak-proof seal. The size of the sealing
member 34 shown here is much smaller than that of the first
preferred embodiment 20 shown on FIGS. 6 and 7, which is a
relatively large rectangular piece of material. The protective
sealing member 34 can be of various size in relation to the size of
the cover 26. In FIG. 6, it is shown of sufficient size to
substantially cover the cover 26. In FIG. 8, it is shown as an
approximately rectangular narrow strip, sealing the holes in the
cover 26, but covering only a small proportion of the cover 26. The
latter was done for clarity in illustrating that the protective
sealing member is not necessarily large. In fact, the protective
member can be so small as to just cover or seal the holes 32 with a
small surplus to allow a finger grip for peeling, or large enough
to totally overlap all portions of the cover 26. The choice of size
and shape depends on the degree of sanitary precautions necessary
and manufacturing considerations.
Another special feature of the third preferred embodiment 38 is
that, enclosed within the rigid base 22 and the flexible cover 26,
it contains an absorbent foam 40, sponge, or like material.
Consequently the third preferred embodiment 38 is eminently
suitable for storing and dispensing low viscosity liquid materials.
Such liquids are squeezed out of the absorbent foam 40 through the
apertures 32 as the user (not shown) presses the applicator against
the surface (not shown) to which the liquid substance 28 is to be
applied.
FIGS. 10 and 11 illustrate a fourth preferred embodiment 42 of the
invention. This embodiment 42 is highly suitable for storing and
dispensing certain medicinal lotions or other materials in
situations where the surface of the flexible cover 26 must be kept
relatively clean. To insure cleanliness, a protective cover 44
(possessing no apertures) is removably attached by heat sealing,
adhesive, or by some other suitable means known in the art, to the
periphery of the base 22. Thus, the protective cover 44 encloses
the flexible cover 26 and the protective sealing member 34.
Referring still primarily to the concept of providing a protective
cover 44 for the dispenser-applicator of the invention, when the
contents 28 are a solid, the protective member 34 can be omitted.
When it is desired to add physical protection, the cover 44
(similar to the one shown on FIG. 11) may be rigid, and may be
snap-fitted to the base. Such a rigid cover is not intended to be
leak-proof.
Referring still to medical uses and others requiring cleanliness,
it is recognized that in the fourth embodiment 42, in FIG. 11, the
handle 24 and base 22 of the dispenser-applicator are not protected
from contamination. It is intended that the fourth embodiment 42
would most likely be used in a situation where quantity of clean
individual dispenser-applicators are contained as a group within
another clean container such as a protective pouch or box. The
protective cover 44 is typically a tough flexible plastic film,
such as 4 mil thick polyester, or a rigid plastic film, such as 18
mil thick Kodar.RTM. PETG copolyester (Eastman Chemical). The
configuration of the seal between the protective cover 44 and base
22, as shown in FIG. 11, is only one possible variation, and the
concept of using a protective cover 44, as shown, should be
understood not to be limited by the specific embodiment 42. The
geometry of the protective cover 44 and the filled
dispenser-applicator is such that when the protective cover 44 is a
thin tough film, it is suitable for peelable removal by peeling
back from one end of the base 22, such that the film 44 collapses
and and everts as it is pulled back so as to pass over the cover
26. When the protective cover 44 is a rigid film, it is removably
attached to the base 22 in such a way that it can be pulled
completely down and away in order to avoid interference and
impingement on the cover 26.
FIGS. 12, 13, and 14 illustrate a fifth preferred embodiment 48 of
the dispenser-applicator of the present invention. In the fifth
preferred embodiment 48 several pockets are formed by attaching one
or more flexible covers 26 to the base 22. Four pockets are
illustrated here by way of example. Each pocket 49, of course,
contains a substance 28 to be stored and dispensed with the
applicator 48. The contents of the several pockets 49 may be
identical with one another. Alternatively, and in certain preferred
embodiments, the several pockets contain individual components of
multi-component systems, for example, the separate components of a
multi-component adhesive system.
Each flexible cover 26 has one or more apertures 32 on the bottom
of each pocket 49, and the apertures or holes 32 for each pocket 49
are sealed preferably with a single protective sealing member 34,
as is shown on FIG. 13 although each pocket could have its own
individual protective sealing member. Use of the fifth preferred
embodiment 48 for dispensing and applying one or more substances 28
from all pockets 49 at the same time is self-explanatory in light
of the foregoing description and the drawing Figures. The fifth
preferred embodiment with identical contents in each pocket is
particularly useful for distributing the contents onto an extremely
rough or irregular surface.
FIGS. 15 and 16 illustrate a sixth preferred embodiment 50 of the
dispenser-applicator of the invention. For reasons of keeping the
substance 28 contained in the sixth embodiment sterile, or tamper
evident, or for some other health, safety, or related reason, the
sixth embodiment 50 has an outer enclosure 52 which provides a
microbial barrier and is capable of maintaining sterility of the
handle 24, the base 22, and the flexible cover 26, and also of the
contents 28 and of the protective sealing member 34. The enclosure
52 is made, for example, from two pieces of plastic, bonded (for
example, glued or heat sealed) to one another, as is shown on the
cross-sectional view of FIG. 16.
In light of the foregoing it should be understood that the
enclosure 52 is intended to provide a microbial barrier to maintain
sterility while simultaneously providing some physical protection
to the dispenser-applicator. As one example, the enclosure 52 is
comprised of two components: a rigid container 54 substantially
deep such that the entire dispenser-applicator is contained within
its volume, and a tough lidstock 56 which is peelably sealed to the
container 54. The container 54 can be made, for example, of
thermoformed 18 mil thick Kodar.RTM. PETG copolyester (Eastman
Chemical), with a lidstock 56 of "Kenpeel 124" (Kenpack
Converters), a heat-sealable 4 mil thick co-extruded film of high
density polyethylene and ethylene-vinyl acetate copolymer. Such an
enclosure can be heat-sealed and is suitable for radiation
sterilization. This enclosure is appropriate under circumstances
where it is desired to utilize gamma radiation to sterilize the
dispenser-applicator.
Referring now to FIGS. 17 and 18, a seventh preferred embodiment 58
of the dispenser-applicator of the present invention is disclosed.
The seventh preferred embodiment 58 is similar in many respects to
the first preferred embodiment, with the following noteworthy
differences. One edge 60 of the base 22 contains a plurality of
notches 62, whereas the other edge 64 has a curved-up lip shape. By
holding the dispenser/applicator at an angle to the desired
surface, and employing lateral motion, the notched edge 60 is
utilized to "scrape" the surface upon which the contents have
already been deposited, and thereby to form relatively
evenly-spaced rows of the contents on the surface, and with
relatively uniform thickness of each row. The curved-up lip 64 is
used where it is desired to spread the substance further on the
surface, particularly in an atraumatic manner. These are but two
possibilities of a variety of edge configurations which can be
utilized in order to further spread the contents in some desired
way. These two configurations would not necessarily be used on the
same dispenser/applicator and are shown in this fashion only for
convenience of illustration.
Referring now to certain aspects of manufacturing the
dispenser-applicators of the present invention, the following is
noted. In the manufacturing process for the invention, whenever a
leak-proof seal is required over the perforations of the cover 26,
it is typical, although not mandatory, that the sealing member 34
is affixed to the cover 26 prior to the insertion of the contents
into the cover. Two principal methods for inserting the contents
into the cover 26 are mentioned. In the first method, the contents
are inserted into the unattached cover, and subsequently bonding of
the cover to the base is accomplished. This method is particularly
useful for but not limited to, solids or semi-solids, or very
viscous materials In the second method, the cover is partially
bonded to the base 22 and the contents are injected (for example,
through a hollow tube) through the remaining non-bonded periphery
between the cover and base. Peripheral bonding is then completed.
This method is particularly useful for liquids or low viscosity
materials. Other filling methods are also possible For example, the
rigid base could possess a small hole through which a smaller
diameter tube is inserted to inject material into the cover, while
air from the cover simultaneously vents out of the hole. The small
hole can then be sealed with a drop of a suitable adhesive. In
another possible method for filling with a solid or semi-solid
material, the base 22 is held in an inverted position relative to
FIG. 1, the desired material is loaded onto the inner surface of
the base, and subsequently the cover is positioned from above, and
is bonded to the base 22.
The invention is not limited to a particular size. Exemplary sizes
for certain specific applicators and for preferred embodiments are
given below. In those applications where a temperature differential
between the dispenser-applicator and the surface is used to melt or
lower the viscosity of the contents of the dispenser-applicator, in
order to create more rapid heat transfer the numerical ratio of the
average width of the cover to the depth of the cover would be
large, for example, on the order of 5 or 10 to 1. A relatively
small version of the dispenser-applicator can be used for buttering
a cob of corn. For example, one set of representative dimensions
for a "butterer" intended to butter one cob of corn are:
handle height, 10-15 mm
base, 30-40 mm square
depth of cover, 5-7 mm
width of perimeter seal, 4-6 mm.
The cover possesses, for example, three holes, each approximately
0.7 mm in diameter, located more or less centrally and
approximately 5 mm from each other.
On the other hand, a larger version of the dispenser-applicator can
be used to apply a medicinal ointment to the back of a burn victim,
for example:
handle height, 30-40 mm
base, 80-100 mm square
depth of cover, 15-20 mm
width of perimeter seal, 5-10 mm.
Hole size, quantity, and spacing, in this embodiment, depends on
factors as discussed elsewhere in this application.
Even larger versions are possible, for example, to apply printing
ink to a large plate or roller, to apply lubricant to a giant
bearing, or to apply adhesive to a large surface (for example,
several square feet). Limitations in size are based primarily on
strengths of bonds in the assembled dispenser-applicator, strengths
of the materials used for cover and base, and convenience of
use.
Several modifications in the construction and use of the
above-described dispenser-applicator device may become readily
apparent to those skilled in the art in light of the foregoing
disclosure. Therefore, the scope of the present invention should be
interpreted solely from the following claims.
* * * * *